Direct acting hydraulic tappet

Abstract: A direct acting hydraulic tappet (20) including a one piece body shell (30) having an outer cylinder (31), an inner cylinder (32) and a plurality of integral axially extending webs (33) that connect the outer cylinder (31) and the inner cylinder (32). A cam face member (41) is attached to one end of the body. An oil hole (40) extends from the outer surface of the outer cylinder (31) through one of the webs (33) to an inner surface of the inner cylinder (32). The hydraulic lash compensating unit (39) is positioned in the inner cylinder (32). The body shell (30) is made from an extruded length of aluminum and is preferably coated with a Teflon impregnated anodized coating. The cam face (41) is made of steel, cast iron or ceramic and is attached to the one end of the body shell by electromagnetic deformation or by the use of adhesive.

Description: This invention relates to direct acting hydraulic tappets. Background and Summary of the Invention Existing direct acting tappets consist of an outer cylinder which is held in a bore in the cylinder head. It is contacted on one end by the camshaft and on the other by the valve. It is allowed to slide axially within the bore, translating the rotary motion of the camshaft into axial motion to the valve. The inside of this outer cylinder is large enough in diameter to surround the engine valve spring. They also contain an inner cylinder which holds a miniature hydraulic lash compensating element. These two cylinders are connected using a radial cross member which is roughly perpendicular to the axis of the cylinder. This cross member effectively closes off the area between the two cylinders on either end. This can be done using one or two pieces, and is normally done using a low cost material. A wear resistant cap is then affixed to the end of the part facing the camshaft. In some applications the camface is integral with the outer cylinder and the perpendicular cross member is integral with the inner cylinder and is attached to the outer cylinder. In other designs the inner and outer cylinders are integral with an attached camface cap. In other designs the cylinder extends past the perpendicular cross member and captures the cap which is supported on the cross member. The joining methods for such tappets include welding, brazing, and staking (mechanical deformation). Because of the difficulty in joining steel to aluminum, proposed aluminum designs for this shell have been of the type using a perpendicular cross member which extends between the lash adjuster and the camface. The camface is simply held in place by the outer cylinder and the valve spring preload. Engine oil is supplied to the hydraulic lash compensating unit through a cavity or reservoir between the outer and inner cylinders. This cavity is bounded by the camface on one end and by the perpendicular cross member on the other. This cavity is filled from a hole in the outer cylinder which is in contact with pressurized engine oil. The outer cylinder is either coated or heat treated to prevent wear from contact with bore in cylinder head. In such tappets a major disadvantage is that the body of the tappet must be machined or cast in order to provide the perpendicular portion. Other disadvantages of the hydraulic tappets is that they are heavy, costly to manufacture, have multiple pieces, and are noisy in operation. In DE-A-2,942,926 there is disclosed an hydraulic tappet assembly having integral, axial ribs. One or more of the ribs includes an oil hole interconnecting the inner and outer cylinders of the tappet. The tappet of DE-A-2,942,926 is of a complex shape, and therefore probably can only be manufactured via an expensive, time consuming process involving several machining operations. Among the objectives of the present invention are to provide a direct acting hydraulic tappet and a method of manufacturing which is lighter; lower in cost; easier to manufacture; quiet in stop-start tests; which can use a steel or cast iron camface; and which can be made of aluminum . In accordance with the invention, a direct acting hydraulic tappet includes a one piece body shell having an outer cylinder interconnected by a plurality of webs. A cam face member is attached to one end of the body. An oil hole extends from the outer surface of the outer cylinder through one of the webs to an inner surface of the inner cylinder. The hydraulic lash compensating unit is positioned in the inner cylinder. The invention is characterized in that the body shell comprises a length cut from an aluminum bar formed by continuous extrusion and in that the webs extend parallel to the axis of the body shell which is preferably coated with a Teflon impregnated anodized coating. The cam face is made of steel, cast iron or ceramic and is attached to the one end of the body shell by electromagnetic deformation or by the use of adhesive. The invention also provides a method according to claim 10 of forming such an hydraulic tappet. Description of the Drawings FIG. 1 is a fragmentary cross sectional view of a direct acting hydraulic tappet in an internal combustion engine. FIG. 2 is a bottom plan view of the tappet. FIG. 3 is a sectional view taken along the line 3-3 in FIG. 2. FIG. 4 is a bottom plan view of the tappet with the hydraulic lash compensating unit removed. FIG. 5 is a sectional view taken along the line 5-5 in FIG. 4. FIG. 6 is a bottom plan view of the tappet shown in FIG. 5 with the cam face member removed. FIG. 7 is a sectional view taken along the line 7-7 in FIG. 6. FIG. 8 is a perspective view of an extrusion utilized in making the body shell of the hydraulic tappet. FIG. 9 is an end view of the extrusion shown in FIG. 8. FIGS. 10-14 are cross sectional views of prior art hydraulic tappets. FIG. 15 is a bar chart of the results of starts to noise tests. FIG. 16 is a bar chart of weight tests. Description Referring to FIGS. 1-7, the direct acting hydraulic tappet 20 embodying the invention is positioned in a bore 21 of an engine for sliding movement axially in the bore 21. The tappet 20 is contacted at one end by a cam 22 on a cam shaft 23. A spring 24 extends into the tappet 20 and yieldingly urges the tappet 20 against cam 22. A valve 25 is operated by the tappet 20, in accordance with conventional construction. The tappet 20 comprises a shell 30 (FIGS. 6, 7) that consists of a one piece extruded body that includes an outer cylinder 31, an inner cylinder 32 and a plurality of axially extending webs 33 integrally connecting the outer cylinder 31 and the inner cylinder 32. Intermediate its ends, the outer cylinder 31 is formed with an annular groove 34. The inner cylinder 32 has a lesser length than the outer cylinder 31. The upper end of each web 33 is machined to form an annular recess 35 adjacent the inner cylinder 32 and a second annular recess 36 of greater axial dimension adjacent the outer cylinder 31. The inner surface 37 of the inner cylinder 32 is formed with a shoulder 38. A hydraulic lash compensating assembly 39 is provided within the inner cylinder 32, as is well known in the art. The shell 30 further includes an oil passage 40 that extends from the groove 34 axially upwardly and inwardly to the upper end of the cavity formed by the inner surface of the cylinder 32 (FIGS. 5, 7). The hydraulic tappet 20 further includes a camface member 41 on the upper end of shell 30 and has an integral annular axial wall 42 extending into the recess 36 and a radial flange 43 engaging the upper end of the outer cylinder 31. Cam face 41 includes a recess 44 on the underside adjacent the upper end of passage 40. The camface member 41 is made of hardened steel, cast iron or ceramic and is attached to the body shell 30 by electromagnetic forming, adhesive bonding or both. The shell is preferably made of a lightweight metal such as aluminum. Referring to FIGS. 8 and 9, the body shell is formed from a bar 50 that is formed by continuous extrusion so that it has an outer cylinder 31a, an inner cylinder 32a and axial webs 33a. The extruded body 50 is cut into lengths and then the body shell is machined from such lengths. The outer surface of the outer cylinder 31 is preferably anodized with Teflon impregnation, Teflon being a registered trademark of Dupont. It can thus be seen that there is thus provided a hydraulic tappet which does not utilize a web that extends perpendicular to the axis of the body and which does not require an oil reservoir or cavity in the shell. FIGS. 10-14 show prior art tappets: FIG. 10 is a drawing of a prior art tappet such as shown in United States patents 4,995,353 and 5,119,774 without the foam filling; FIG. 11 is a drawing of the prior art tappet shown in United States patent 4,602,409; FIG. 12 is a drawing of the prior art tappet shown in United States patents 4,590,898 and 4,270,496; FIG. 13 is a drawing of a prior art tappet such as shown in United States patent 4,367,701; and FIG. 14 is a drawing of prior art tappet shown in FIG. 11a of SAE Technical Paper Series 900451 titled Performance of Hydraulic Lash Adjusters With Regard to Valve Train Noise at Cold Starts and Short Term Start, International Congress and Exposition, Detroit, Michigan, February 26-March 2, 1990. FIG. 15 is a comparative summary of Starts to Noise of various tappets wherein: A is a tappet of the present invention. B is a tappet shown in FIG. 11. C is tappet shown in FIG. 14. D, E are tappets shown in FIG. 12. F is tappet shown in FIG. 10. These tests used the following procedure: 1. Warm engine: 90°C 2. Let engine sit: 20 min. 3. Start engine and run for: 5 sec. 4. Let engine sit: 20 min. 5. Repeat steps 3 and 4 for: 40 starts 6. Record for the start number when noise first occurs, and when the engine fails to quiet during the run time. In FIG. 15, the clear bar represents the start number when the engine failed to quiet within the 5 second duration of the test. The cross hatched bar indicates the start number when noise was first noticed, but the engine did quiet during the 5 seconds. It can be sen that the tappet embodying the invention exceeded 40 starts. FIG. 16 is a graphic summary of comparative weight tests of these tappets. In FIG. 16, the clear bar indicates the weight of the tappet when filled with engine oil. The cross hatched bar is the weight of the tappet when empty. It can be seen that the tappet embodying the invention has the least weight. Referring to FIGS. 10-16 it can be seen that each of the prior art designs has a shell defining a reservoir and having a transverse or radial wall perpendicular to the axis of the shell. The disadvantage of existing designs is that the rough shape of the part must be machined or formed, one piece at a time. The new design in accordance with the present invention eliminates the perpendicular (radial) cross member and replaces it with cross members or webs that are parallel (axial) with respect to the inner cylinder and outer cylinder leaving both ends of the part open. This allows the basic form of this part to be continuously extruded in bar form. This significantly reduces the cost of manufacturing this part. The wear resistant camface is then attached using an innovative attachment method. Current methods of attachment include welding, brazing or capturing the camface within the outer cylinder and supporting it on the perpendicular cross member. This new method of the present invention uses electromagnetic forming and/or adhesive bonding to attach the cap to the cylinder. This allows attaching an aluminum housing directly to a wear resistant steel or cast iron cap without the perpendicular cross member between the cap and the hydraulic element. This reduces both the height and weight of the tappet. Reduced tappet height in this type of application directly reduces the overall engine height which allows for a more aerodynamic hood shape. The lighter weight allows for higher engine RPM's due to less reciprocating mass. The oil is supplied directly to the hydraulic element through a hole 40 in one or more of the axial cross member or webs 33. This eliminates the need for a cavity or reservoir in the shell. This further reduces the operational weight of the tappet. It also reduces the start up noise of the tappet. In current designs, the reservoir drains when the engine is shut off, this reservoir must refill before oil can reach the hydraulic element. In this design of the present invention, there is no reservoir to refill, so oil is supplied much more quickly to the lash element. The outside surface of the outer cylinder of the present invention uses a novel coating, namely, Teflon impregnation during the anodizing process is used to reduce friction and wear of this surface. It has been found that the hydraulic tappet embodying the invention is less costly to manufacture; has less weight; easier to manufacture and is very quiet in start-stop tests.

Claims: A direct acting hydraulic tappet (20), for an internal combustion engine, comprising a one piece body shell (30) having an outer cylinder (31) and an inner cylinder (32) interconnected by a plurality of webs (33); a camface member (41) attached to one end of the body shell (30); an oil hole (40) extending from the outer surface of the outer cylinder (31) through one of the webs (33) to an inner surface of the inner cylinder (32); and an hydraulic lash compensating unit (39) positioned in the inner cylinder (32), characterised in that: i) the body shell (30) comprises a length cut from an aluminum bar formed by continuous extrusion; and ii) the webs (33) extend parallel to the axis of the body shell. The hydraulic tappet set forth in claim 1 wherein said outer cylinder (31) has an outer surface which is anodized and impregnated with polytetrafluoroethylene. The hydraulic tappet set forth in claim 1 wherein said camface member (41) comprises hardened steel. The hydraulic tappet set forth in claim 1 wherein said camface member (41) comprises cast iron. The hydraulic tappet set forth in claim 1 wherein said camface member (41) comprises ceramic. The hydraulic tappet set forth in claim 1 wherein said camface member (41) is joined to said body by electromagnetic deformation formed on said body shell (30). The hydraulic tappet set forth in claim 1 wherein said camface member (41) is adhered to said body shell (30). The hydraulic tappet set forth in claim 1 wherein said camface member (41) is adhesively bonded to said body shell (30). The hydraulic tappet set forth in claim 1 wherein said webs (33) are flat. A method of forming an hydraulic tappet (20), for an internal combustion engine, comprising continuously extruding a bar of aluminium having a cross-section defining an outer cylinder (31); an inner cylinder (32); and integral webs (33) interconnecting the inner (32) and outer (31) cylinders and extending parallel to the axis of the bar; severing a portion of the bar to define a tappet body shell (30); bonding a cam face member (41) on the body shell; and forming an oil hole (40) extending from the periphery of the outer cylinder (31) to the inner surface of the inner cylinder (32). The method set forth in claim 10 including the step of attaching a camface member (41) to one end of said body shell. The method set forth in claim 11 wherein the step of attaching said camface member (41) is by electromagnetic forming. The method set forth in claim 11 wherein the step of attaching said camface member (41) to said body shell (30) is by adhesively bonding the camface member (41) to the shell (30).

Inventors: FULLMER TIMOTHY J, ROOS ROBERT C, SCHULTZ KRAIG D, FULLMER, TIMOTHY J., ROOS, ROBERT C., SCHULTZ, KRAIG D.
Applicants: SEALED POWER TECH LTD, SEALED POWER TECHNOLOGIES, LIMITED PARTNERSHIP
Application year: 1994
Main classification: F01L1
IPC codes: F01L1, B21D53